Power Tool Temperature Sensor Layout for Overheat Detection

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Solution Overview

Problem

Existing power tools lack effective temperature monitoring and control systems to prevent overheating or underheating conditions, which can lead to component degradation and operational failures.

Innovation Solution

Incorporation of multiple temperature sensors and a controller to monitor temperature differences and generate notifications or adjust power supply based on temperature thresholds, calculate heat generation, and predict potential errors by analyzing temperature statistics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple temperature sensors and control systems are added to monitor and regulate temperature, then reliability and safety are improved, but device complexity increases

Engineering Contradiction:

Improvetemperature monitoring reliabilityVSAvoidsensor and control system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the temperature monitoring function into multiple independent temperature sensors positioned at different locations within the power tool. Each sensor monitors specific components (motor, battery, electronics) separately, allowing targeted monitoring without requiring a single complex centralized system. This segmentation improves reliability through distributed monitoring while keeping individual sensor complexity low.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller is configured to proactively detect temperature differences before they reach dangerous levels and take preventive actions such as generating warnings or limiting power output. By performing preliminary detection and action, the system prevents overheating conditions rather than responding after failure occurs, thereby improving reliability through preventive maintenance.

Inventive Principle:

Principle #10Preliminary action

2Duration of action of stationary object

If temperature monitoring and control systems are implemented, then component lifespan is extended through prevention of overheating, but productivity may be reduced due to power limiting

Engineering Contradiction:

Improvecomponent lifespanVSAvoidpower tool output

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The system dynamically adjusts power output based on real-time temperature conditions. When temperatures are within safe ranges, the power tool operates at full capacity for maximum productivity. When temperature differences indicate potential overheating, the controller dynamically limits power only to the affected components while maintaining safe operation. This dynamic adjustment extends component lifespan while minimizing impact on overall productivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The controller monitors temperature parameters and changes operational parameters (power output, current limits) based on detected temperature differences. By changing operational parameters in response to temperature conditions, the system extends component lifespan through controlled operation while maintaining optimal productivity within safe temperature boundaries.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances the safety and reliability of power tools by preventing overheating or underheating through proactive control measures, thereby extending component lifespan and ensuring stable operation.

Implementation Method 1

a first temperature sensor configured to sense a temperature of the first electrical component

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 2

a second temperature sensor configured to sense a temperature of the second electrical component

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 3

calculate an amount of heat generated by the electrical component

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12466047B2Power tools including a plurality of temperature sensors

Publication Date: 2025.11.11 MILWAUKEE ELECTRIC TOOL CORP

AI summary

Systems and methods for implementing a plurality of temperature sensors in power tools. An example power tool includes a first electrical component, a second electrical component, and an indication device. The power tool includes a first temperature sensor configured to sense a temperature of the first electrical component, and a second temperature sensor configured to sense a temperature of the second electrical component. A controller is connected to the first temperature sensor and the second temperature sensor. The controller is configured to determine a temperature difference between a first temperature value associated with the first temperature sensor and a second temperature value associated with the second temperature sensor, compare the temperature difference to a temperature difference threshold, and provide, when the temperature difference satisfies the temperature difference threshold, a notification using the indication device.